API SC5 Ballot Submission Task Group on Drill Stem Elements

Transcription

1 API SC5 Ballot Submission Task Group on Drill Stem Elements Work Item Number 7040 Title of Work Item Type of Distribution [Voting and Comment, Comment-only, Recirculation (comment resolution), Re-ballot] Impacted Documents Revision Key Spec 5DP 2 nd Edition Development Ballot; commenting and voting. None Technical updates shown with yellow highlights, but may not be exhaustive, and should be compared to the first edition. Updates for style and formatting are not highlighted. NOTE See the ballot notification for additional information regarding this ballot.

2 required to become an API Standard. It shall not be reproduced or circulated or quoted. in whole or in part, outside of API committee activities except with the approval of the Chairman of the committee having jurisdiction and staff of the API Standards Dept. Copyright Drill Pipe API SPECIFICATION 5DP SECOND EDITION, [MONTH][YEAR] API MONOGRAM PROGRAM EFFECTIVE DATE: [MONTH][YEAR] THE SPECIAL NOTES, FOREWORD, AND TABLE OF CONTENTS WILL BE INSERTED BY API DURING THE PAGE PROOF STAGE.

3 1 Scope 1.1 Coverage Drill Pipe This standard specifies the technical delivery conditions for steel drill pipe with upset pipe body ends and welded on tool joints for use in drilling and production operations in petroleum and natural gas industries for three product specification levels (PSL-1, PSL-2, PSL-3). The requirements for PSL-1 form the basis of this standard. The requirements that define different levels of standard technical requirements for PSL-2 and PSL-3 are provided. This standard covers the following grades of drill pipe: grade E; high-strength (grades G, S, V, X, and HA); sour service (grades SS) This standard can also be used for drill pipe with tool joints not specified by other standards. By agreement between purchaser and manufacturer, this standard can also be applied to other drill pipe body and/or tool joint dimensions. This also standard list supplementary requirements that may be agreed upon between the purchaser and manufacturer for testing, performance verification, and non-destructive examination. This standard does not consider performance properties. NOTE 1 NOTE 2 NOTE 3 In this standard, drill pipe is designated by label 1, label 2, grade of material (E, X, G, S and V), upset type, and type of rotary shouldered connection; designations are used for identification in ordering. See API 7-2 for the detailed requirements for the threading and gauging of drill pipe tool joints. See API 7G for the performance properties of the drill pipe. 1.2 Application of the API Monogram If the product is manufactured at a facility licensed by API and is intended to be supplied bearing the API Monogram, the requirements of Annex A apply. 2 Normative References The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any errata or addenda) applies. API Recommended Practice 7G, Drill Stem Design and Operating Limits API Specification 7-2, Threading and Gauging of Rotary Shouldered Thread Connections API Technical Report 5C3, Calculating Performance Properties of Pipe Used as Casing or Tubing ASME Boiler and Pressure Vessel Code, Section IX ASNT SNT-TC-1A, Personnel Qualification and Certification in Non-Destructive Testing ASTM A370, Standard Test Methods and Definitions for Mechanical Testing of Steel Products ASTM A751, Standard Test Methods, Practices and Terminology for Chemical Analysis of Steel Products ASTM A941, Terminology Relating to Steel, Stainless Steel, Related Alloys, and Ferroalloys ASTM E4, Standard Practices for Force Verification of Testing Machines

4 ASTM E10, Standard Test Method for Brinell Hardness of Metallic Materials ASTM E18, Standard Test Methods for Rockwell Hardness of Metallic Materials ASTM E23, Standard Test Methods for Notched Bar Impact Testing of Metallic Materials ASTM E83, Standard Practice for Verification and Classification of Extensometer Systems ASTM E92, Standard Test Method for Vickers Hardness of Metallic Materials ASTM E213, Standard Practice for Ultrasonic Examination of Metal Pipe and Tubing ASTM E309, Standard Practice for Eddy-Current Examination of Steel Tubular Products Using Magnetic Saturation ASTM E570, Standard Practice for Flux Leakage Examination of Ferromagnetic Steel Tubular Products ASTM E709, Standard Guide for Magnetic Particle Testing ISO , Metallic materials Brinell Hardness test Part 1: Test method ISO , Metallic materials Vickers hardness test Part 1: Test method ISO , Metallic materials Rockwell hardness test Part 1: Test method (scales A, B, C, D, E, F, G, H, K, N, T) ISO 6892, Metallic materials Tensile testing ISO , Metallic materials Verification of static uni-axial testing machines Part 1: Tension/compression testing machines Verification and calibration of the force-measuring system ISO 9303, Seamless and welded (except submerged arc-welded) steel tubes for pressure purposes Full peripheral ultrasonic testing for the detection of longitudinal imperfections ISO 9304, Seamless and welded (except submerged arc-welded) steel tubes for pressure purposes Eddy current testing for the detection of imperfections ISO 9305, Seamless steel tubes for pressure purposes Full peripheral ultrasonic testing for the detection of transverse imperfections ISO 9402, Seamless and welded (except submerged arc-welded) steel tubes for pressure purposes Full peripheral magnetic transducer/flux leakage testing of ferromagnetic steel tubes for the detection of longitudinal imperfections ISO 9513, Metallic materials Calibration of extensometers used in uniaxial testing ISO 9598, Seamless steel tubes for pressure purposes Full peripheral magnetic transducer/flux leakage testing of ferromagnetic steel tubes for the detection of transverse imperfections ISO 9769, Steel and iron Review of available methods of analysis ISO 10400, Petroleum and natural gas industries Equations and calculations for the properties of casing, tubing, drill pipe and line pipe used as casing or tubing ISO , Petroleum and natural gas industries Rotary drilling equipment Part 2: Threading and gauging of rotary shouldered thread connections ISO 11484, Steel tubes for pressure purposes Qualification and certification of non-destructive (NDT) personnel ISO 13665, Seamless and welded steel tubes for pressure purposes Magnetic particle inspection of the tube body for the detection of surface imperfections

5 3 Terms, Definitions, Symbols and Abbreviations 3.1 Terms and Definitions For the purposes of this document, the following terms and definitions apply bevel diameter outer diameter of the sealing shoulder of a rotary shouldered connection defect imperfection of sufficient magnitude to warrant rejection of the product based on criteria defined in this standard drill pipe drill pipe body with weld-on tool joints drill pipe body seamless pipe with upset ends drill pipe body manufacturer firm, company or corporation that operates facilities for making the drill pipe body and is responsible for compliance with the requirements of this standard drill pipe manufacturer firm, company or corporation responsible for compliance with all the applicable requirements of this standard drill pipe torsion-strength ratio torsion strength of the tool joint connection divided by the drill pipe body torsion strength drill pipe weld neck machined part of the drill pipe comprising the tool joint weld neck, the weld and the drill pipe body upset elephant hide wrinkled outside diameter surfaces of the drill pipe body caused by the upsetting process essential variable variable parameter in which a change affects the mechanical properties of the weld joint gouge elongated groove or cavity caused by mechanical removal of metal

6 hard banding (hard facing) application of material onto tool joints to reduce external wear of the tool joint hardness number result from a single hardness impression heat (heat of steel) metal produced by a single cycle of a batch-melting process heat analysis chemical analysis representative of a heat as reported by the metal producer imperfection discontinuity in the product wall or on the product surface that can be detected by an NDE method included in this standard indication evidence of a discontinuity that requires interpretation to determine its significance inspection process of measuring, examining, testing, gauging or otherwise comparing the product with the applicable requirements label 1 dimensionless designation for the drill pipe body size that may be used when ordering label 2 designation for the drill pipe body wall thickness that may be used when ordering NOTE This was historically related to the mass per unit length linear imperfection imperfection that includes, but is not limited to, seams, laps, cracks, plug scores, cuts, gouges and elephant hide (see API 5T1) lot definite quantity of product manufactured under conditions that are considered uniform for the attribute being inspected lot size number of units in a lot

7 manufacturer one or more of the following, depending on the context: the maker of drill pipe, the maker of drill pipe body, or the maker of tool joints mean hardness number result of averaging the hardness numbers for the single specimen or location being evaluated non-essential variable variable parameter in which a change may be made in the WPS without re-qualification non-linear imperfection imperfection that includes, but is not limited to, pits (see API 5T1) pipe body seamless pipe excluding upset and upset-affected areas procedure qualification record (PQR) written documentation stating an assessment that a specific WPS produces welds in accordance with the requirements of this standard product drill pipe, drill pipe body, or tool joint purchaser party responsible for both the definition of requirements for a product order and for payment for that order quench crack crack in steel resulting from stresses produced during the transformation from austenite to martensite NOTE This transformation is accompanied by an increase in volume rotary shouldered connection connection used on drill string elements which has tapered threads and sealing shoulders rotary friction welding solid state welding under compressive force contact of work pieces rotating relative to one another along a common axis to increase temperature and plastically displace material from the faying surfaces NOTE Either direct drive or inertia friction welding is acceptable sample one or more units of product selected from a lot to represent that lot

8 seamless pipe wrought steel tubular product made without a weld seam NOTE It is manufactured by hot working and, if necessary, by subsequently cold working or heat treating, or a combination of these operations, to produce the desired shape, dimensions and properties tool joint forged or rolled steel component for drill pipe designed to be welded to the drill pipe body and having a rotary shouldered connection tool joint box threaded connection on tool joints that has internal threads tool joint manufacturer firm, company or corporation that operates facilities for making tool joints and is responsible for compliance with the requirements of this standard applicable to the tool joint tool joint pin threaded connection on tool joints that has external threads upset ovality difference between the largest and smallest diameter in a plane perpendicular to the axis of the upset weld zone zone comprising the weld line and the heat-affected areas on either side of the weld line caused by the friction welding and subsequent heat-treatment processes welding machine performance qualification welding operator performance qualification (WPQ) written procedure used to demonstrate that a welding machine and welding operator combination has the capability to use the WPS to produce a weld meeting the requirements of this standard NOTE It includes records from the qualification tests welding procedure specification (WPS) written procedure that provides instructions to the welding operator for making production welds in accordance with the requirements of this standard NOTE It includes all essential and nonessential variables for friction welding of tool joints to drill pipe body; a WPS applies to all those welds, of which each element has the same specified dimensions and chemistry, that are grouped according to a documented procedure to ensure a predictable response to weld zone treatment for a particular grade. 3.2 Symbols and Abbreviations A cross-sectional area of the tensile specimen, expressed in square millimeters (square inches)

9 A Ad p A w D C m C D dp D f D j D D te D ou d dp d j d p d te d ou EU e e m e w G IEU IU L L b Le u L iu L pb L pe m eu m iu N R length of reduced section, expressed in millimeters cross-sectional area of the drill pipe body based on the specified dimensions of the pipe body minimum cross-sectional area of the weld zone tool joint outside diameter (pin and box) standard Charpy impact energy, expressed in Joules standard Charpy impact energy, expressed in foot-pounds pipe body outside diameter bevel diameter (pin and box) external diameter on the tool joint neck, which becomes D te after welding and final machining diameter of round bar outside diameter of the drill pipe weld after machining drill pipe body upset outside diameter pipe body inside diameter internal diameter of the tool joint neck, which becomes d te after welding and final machining tool joint pin inside diameter inside diameter of the drill pipe weld after machining drill pipe body upset inside diameter external upset minimum extension in a gauge length of 50.8 mm (2.0 in.) minimum elongation drill pipe body mass gain or loss due to end finishing, for plain end non-upset pipe, e w equals zero gauge length internal external upset internal upset length of drill pipe with welded on tool joint (from shoulder to shoulder) length of box tool joint outside diameter including connection bevel and hard band drill pipe body external upset length drill pipe body internal upset length length of pin tool joint outside diameter, including connection bevel length of drill pipe body (without tool joint) drill pipe body external upset taper length drill pipe body internal upset taper length fraction or number with a fraction minimum radius of fillet

10 RSC T S t U U dp W W L w dp w pe Y min Y w rotary shouldered connection tensile strength pipe body wall thickness upset dimension minimum specified tensile strength width approximate calculated mass of a piece of drill pipe body of length, L pe approximate linear mass of the drill pipe plain end pipe body unit mass (without upsets) specified minimum yield strength weld zone yield strength 4 Conformance 4.1 References to Annexes For additional requirements or information concerning the manufacturing of casing and tubing, as referenced, see the following. figures in SI (USC) Units, see Annex B (normative) product tables in USC units, see Annex C (normative) product tables in SI units, see Annex D (normative) product supplementary requirements (SR), see Annex E (informative) conversion procedures for USC to SI units, see Annex F (informative) product specification levels (PSLs), see Annex G (informative) purchaser inspection, see Annex H (normative) bevel diameters for tool joints with non-preferred connections, see Annex I (informative) 4.2 Dual Referencing In the interests of worldwide application of this technical report, the API Subcommittee on Tubular Goods (SC5) has decided, after detailed technical analysis, that certain documents listed in Section 2 and prepared by API SC5 or other technical committees are interchangeable in the context of the relevant requirement with the relevant document prepared by the International Organization for Standardization (ISO) or the American Society for Testing and Materials (ASTM). These latter documents are cited in the running text following the API reference and preceded by or for example, API XXXX or ISO YYYY or ISO YYYY or ASTM ZZZZ. Application of an alternative document cited in this manner may lead to technical results different from the use of the preceding API reference. However, both results are acceptable, and these documents are thus considered interchangeable in practice.

11 4.3 Units of Measurement In this standard, data are expressed in both the International System (SI) of units and the United States Customary (USC) system of units. For a specific order item, it is intended that only one system of units be used without combining data expressed in the other system. Products manufactured to specifications expressed in either of these unit systems shall be considered equivalent and totally interchangeable. Consequently, compliance with the requirements of this standard as expressed in one system provides compliance with requirements expressed in the other system. In the text, data in SI units are followed by data in USC units in brackets. 5 Information to be Supplied by the Purchaser 5.1 When placing orders for drill pipe to be manufactured in accordance with this standard, the purchaser shall specify the following from Table 1 in the purchase agreement: Table 1 Purchaser Supplied Information for Drill Pipe (required) Requirement Reference Document number(s) API 5DP or ISO Quantity Label 1 Table C.1 or Table D.1 Label 2 Table C.1 or Table D.1 Grade Table C.1 or Table D.1 Upset type (internal, external or internal-external upset) Table C.1 or Table D.1 RSC type or other special connection by agreement between 6.2.2, or Table C.1 or Table D.1 purchaser and manufacturer Range or special length and tolerance by agreement between Table C.3 or Table D.3 purchaser and manufacturer Delivery date and shipping instructions Inspection by purchaser Annex H Documentation When placing orders for drill pipe to be manufactured in accordance with this standard, the purchaser may specify any of the following from Table 2 in the purchase agreement: Table 2 Purchaser Supplied Information for Drill Pipe (optional) Requirement Reference Tool joint outside diameter Tool joint inside diameter of the pin end Length of pin tool joint outside diameter Length of box tool joint outside diameter Under-thickness tolerance if less than 12.5 % Type of heat treatment for drill pipe body: grade E only Hard banding: type, location, dimensions, and acceptance criteria NOTE Hard banding reduces the length of the tool joint outside diameter available for tong placement. Pipe coatings: internal and/or external 6.4.5, 6.4.6, and Special threads on tool joints Specific thread or storage compound Thread protector type and 8.4.8

12 Marking requirements 6.15, 7, and 8.13 Individual drill pipe traceability 6.5 Supplementary Requirement Reference Non-destructive examination for Grades E, X, and G Clause E.2 (SR 2) Test certificates Clause E.3 (SR 15) Charpy V-notch (CVN) impact toughness testing of Grade E pipe Clause E.4 (SR 19) body Alternative low temperature Charpy V-notch impact testing Clause E.5 (SR 20) Weld zone testing frequency Clause E.6 (SR 23) Charpy V-notch: increased weld zone requirements Clause E.7 (SR 24) For PSL-2 or PSL-3 Annex G 5.3 When placing orders for drill pipe bodies to be manufactured in accordance with this standard, the purchaser shall specify the following from Table 3 in the purchase agreement: Table 3 Purchaser Supplied Information for Drill Pipe Body (required) Requirement Reference Document number(s) API 5DP Quantity Label 1 or specified OD Table C.1 or Table D.1 Label 2 or specified wall thickness Table C.1 or Table D.1 Grade Table C.1 or Table D.1 Upset type (internal, external or internal-external upset) Table C.1 or Table D.1 Length and tolerance Delivery date and shipping instructions Inspection by purchaser Annex H Documentation When placing orders for drill pipe bodies to be manufactured in accordance with this standard, the purchaser may specify any of the following from Table 4 in the purchase agreement: Table 4 Purchaser Supplied Information for Drill Pipe Body (optional) Requirement Reference Special upset configuration Under thickness tolerance if less than 12.5 % Type of heat treatment for drill pipe body: Grade E only Impact requirements for grade E Clause E.4 (SR 19) Alternative requirements for impact test Clause E.5 (SR 20) PSL-2 or PSL-3 Annex G 5.5 When placing orders for tool joints to be manufactured in accordance with this standard, the purchaser shall specify the following from Table 5 in the purchase agreement: Table 5 Purchaser Supplied Information for Tool Joints (required) Requirement Document number(s) API 5DP Quantity Drawing of the tool joint pin, including any necessary details Figure B.12 Drawing of the tool joint box, including any necessary details Figure B.12 Reference

13 Delivery date and shipping instructions Inspection by purchaser Annex H Documentation When placing orders for tool joints to be manufactured in accordance with this standard, the purchaser may specify any of the following from Table 6 in the purchase agreement: Table 6 Purchaser Supplied Information for Tool Joints (optional) Requirement Reference Special surface treatment Tool joint break-in Hard banding: type, location, dimensions, and acceptance criteria NOTE Hard banding reduces the length of tool joint outside diameter available for tong placement. Thread-protector type Marking requirements 8.13 Alternative requirements for impact testing Clause E.5 (SR 20) PSL-2 or PSL-3 Annex G 6 Requirements for Drill Pipe 6.1 General The drill pipe shall be made from drill pipe body manufactured in accordance with Clause 7 and tool joints manufactured in accordance with Clause. Areas of the drill pipe body and tool joint affected by the welding and finishing processes are addressed in Clause Dimensions, masses and connections Standard configuration The configuration of drill pipe shall correspond to Figure B.1. Drill pipe shall be furnished with dimensions and tolerances as in Tables C.1 and C.2, or Tables D.1 and D.2, and/or in the purchase agreement. All dimensions shown without tolerances are related to the basis for design and are not subject to measurement to determine acceptance or rejection of product. Drill pipe dimensions that are not in this standard or in the purchase agreement are at the manufacturer's discretion. Rotary shouldered connections shall conform to the dimensions, together with the tolerances, in API 7-2. Right-hand thread connections shall be considered standard. When connections not defined in this standard, but described as non-preferred in API 7-2, are used, the bevel diameters should be as described in Annex I Alternative configurations When specified in the purchase agreement, drill pipe shall be furnished in dimensional configurations not defined in this standard. In this case, dimensions, tolerances and markings shall be agreed between the purchaser and manufacture. The drill pipe body and tool joint shall be modified in accordance with this agreement, but the drill pipe shall otherwise be manufactured in accordance with the requirements of this standard.

14 The outside diameter of the box tool joint, d, and inside diameter of the pin tool joint, d p, dimensions in Table C.1 or Table D.1, result in a drill pipe torsion-strength ratio 0.8 or greater. Changes in the OD and ID of the tool joints can result in a lower drill pipe torsion-strength ratio, which should be determined by the purchaser to be suitable for the intended application Drill pipe weld neck diameters The drill pipe weld diameters, D te and d te. as shown in Figure B.1, apply to the finished product after the tool joint is welded to the drill pipe body and machined and/or ground. The outside diameter, D te, shall meet the requirements of Table C.1 or Table D.1, and The inside diameter, d te, shall meet the requirements of and may be different on the pin and box weld zones Tool joint inside diameters The tool joint pin inside diameter, d p, shall meet the requirements in Table C.1 or Table D.1. The tool joint box inside diameter is at the manufacturer s discretion but shall not be less than the tool joint pin internal diameter, d p Length Drill pipe shall be furnished in length ranges conforming to Table C.3 or Table D.3, or other lengths and tolerances as specified in the purchase agreement. The drill pipe manufacturer shall specify the lengths and tolerances of the drill pipe body and tool joints such that the required length of each drill pipe is achieved Length of tool joint outside diameter The length of pin tool joint outside diameter, L pb. and the length of box tool joint outside diameter, L B, in Table C.1 or Table D.1, may be increased by agreement between purchaser and manufacturer End drift Each drill pipe shall be end drift tested throughout the length of the tool joints and upsets with a cylindrical mandrel having a minimum diameter of 3.2 mm (0.125 in.) smaller than the specified inside diameter of the pin end, d p. The drift mandrel shall be at least 100 mm (4 in.) long. NOTE Drift testing of the full length of the drill pipe is not required Tool joint alignment The maximum misalignment between the longitudinal axis of the drill pipe body and the longitudinal axis of the welded-on tool joint shall not exceed the following: a) for parallel misalignment: 4 mm (0.157 in.), total indicator reading (TIR); b) for angular misalignment: 8 mm/mm (0.008 in./in.), TIR for label 1: 4-1 /2 and larger; 10 mm/mm (0.010 in./in.), TIR for smaller than label 1: 4-1 /2. The axis of the tool joint shall be determined by two locations on the surface of the outside diameter, d, that is unaffected by markings or hard banding. The axis of the drill pipe body shall be determined over a minimum length of 400 mm (15 in.) on the outside surface of the pipe body.

15 6.2.9 Weld zone profile The weld zone shall have no sharp corners or drastic changes of section. The internal weld zone profile shall not cause a 90 hook-type tool to hang up. 6.3 Material requirements General The material properties of the drill pipe body and the tool joint shall be as in Tables C.4 to C.8, or Tables D.4 to D.8, inclusive. The weld zone is defined for the purposes of this section as the heat-affected zone of the weld and the region that is austenitized by the post weld heat treatment. NOTE This region can extend beyond the gauge length of a standard tensile specimen Weld zone yield strength The yield load of the weld zone in tension shall be greater than the yield load of the drill pipe body as given by Equation (1). If the weld zone is larger than the gauge length, multiple samples may be required to include the transition zones. The lower yield strength shall be reported. (Y w A w ) > (Y min Ad p ) (1) where Ad p is the cross-sectional area of the drill pipe body based on the specified dimensions of the pipe body; A w is the minimum cross-sectional area of the weld zone; Y min is the specified minimum yield strength of the drill pipe body; Y w is the weld zone minimum yield strength (determined by the manufacturer based on the design). The method for calculating the minimum cross-sectional area, A w, of the weld zone shall be as given in Equation (2): 2 2 A W = D te,min d te,max (2) where d te,max is the maximum allowable inside diameter specified by the drill pipe manufacturer; D te,min is the minimum allowable outside diameter specified by the drill pipe manufacturer Weld zone hardness For surface hardness, no hardness number shall exceed 37 HRC, or equivalent, for Grades E, X, G and S, or 40 HRC for Grade HA. For SS grades, the surface hardness shall not exceed 28.0 HRC. For the through-wall hardness test, the mean hardness number of the weld zone shall not exceed 37 HRC, or equivalent, for Grades E, X, G and S, or 40 HRC for Grade HA. For SS grades, the mean hardness of the weld zone shall not exceed 28.0 HRC, with no single value exceeding 30.0 HRC Weld zone Charpy V-notch absorbed energy requirements The minimum absorbed energy requirements shall be as in Table C.8 or Table D.8. In addition, not more than one impact specimen shall exhibit an absorbed energy below the minimum average absorbed energy

16 requirement, and in no case shall an individual impact specimen exhibit an absorbed energy below the minimum specimen absorbed energy requirement. Additional requirements for PSL-3 are in Annex G Weld zone Charpy V-notch absorbed energy Alternative requirements When specified in the purchase agreement, the absorbed energy shall meet SR 20 (Section E.5) or SR 24 (Section E.7) requirements (see also Table C.8 or Table D.8) Weld zone transverse side bend properties The guided bend specimens shall have no open discontinuity in the weld zone exceeding 3 mm (0.125 in.) measured in any direction on the convex surface of the specimen after bending. Open discontinuities occurring on the corner of the specimen during testing shall not be considered unless there is definite evidence that they result from lack of fusion, inclusions or other internal discontinuities Weld zone H2S resistance for SS Grades When specified by E.9 (SR 26), the sulphide stress cracking resistance of the weld shall be periodically tested. 6.4 Process of manufacture for drill pipe Processes requiring validation Final operations performed during drill pipe manufacturing that affect compliance as required in this standard (except chemical composition and dimensions) shall have their process validated. Those processes requiring validation are welding and weld heat treatment Welding qualification The manufacturer shall develop, qualify and use a welding procedure. including post weld heat treatment (WPS and PQR), in accordance with the ASME BPVC, Section IX. The procedure shall identify the essential variables and non-essential variables and address the permissible number of reheat treatments. The PQR shall include, as a minimum, the data of the specific variables (both essential and non-essential) used to weld a tool joint to a drill pipe body and the results of all mechanical tests to verify the properties in 6.3 carried out on specimens taken from the test weld. In addition, the manufacturer shall undertake macrostructrual examination of the weld to verify that the weld exhibits complete bonding and freedom from cracks. The manufacturer shall qualify the welding machines and welding operators to a specific WPQ for each WPS utilized by the operators Welding of tool joints to drill pipe body and post weld heat treatment The welding of the tool joint to the drill pipe body shall be by the rotary friction welding process. A post weld heat treatment shall be performed through the entire thickness and from the weld line to beyond where the flow lines of the tool joint and drill pipe body material change direction because of the welding process. The weld shall be austenitized, cooled below the transformation temperature and tempered at a minimum temperature of 593 C (1100 F).

17 6.4.4 Weld machining The weld area shall be machined and/or ground, both externally and internally, to produce a flush surface (visually free from gouges or abrupt changes in section). Tool marks from normal machining operations shall be acceptable Internal coating When specified in the purchase agreement, drill pipe shall be internally coated over the full length, except the thread. The type of coating shall be specified in the purchase agreement and the application and inspection shall be carried out in accordance with an agreed documented procedure External coating Unless otherwise specified in the purchase agreement, the drill pipe shall be given an external coating for protection from corrosion during transit. The coating shall be rated to protect the drill pipe for at least three months and it should be smooth, hard to the touch and with minimum sags Thread protection Threads and shoulders of rotary shouldered connections shall be equipped with thread protectors to protect them from damage during transportation and storage. Unless otherwise specified in the purchase agreement, the type of thread protector is at the manufacturer s discretion. A thread compound, suitable for rotary shouldered connections, shall be applied over the clean threads and shoulders before protectors are installed. Unless otherwise specified in the purchase agreement, the type of thread compound is at the manufacturer s discretion. When specified in the purchase agreement, a storage compound shall be applied instead of the thread compound. 6.5 Traceability The drill pipe manufacturer shall establish and follow procedures for maintaining traceability to any applicable supplementary requirement and/or PSL requirement, as well as to drill pipe body heat and tool joint heat as in Clauses 7 and 8, respectively. Lot identity of all welds shall be maintained until all required tests are performed and conformance with specified requirements has been documented. The procedures shall provide means for tracing the welds to the lot and to mechanical and inspection test results. When additional traceability is required, the details shall be agreed and be specified in the purchase agreement. 6.6 Inspection and testing General Inspection and test equipment calibration The manufacturer shall determine and document the appropriate calibration frequency and procedures (including occurrences of out-of-calibration and the consequences on products) to be able to certify that all products conform to the requirements of this standard.

18 6.6.2 Dimensional inspection The drill pipe weld diameters, D te and d te, shall be verified, after final machining and/or grinding according to a documented procedure. to meet the requirements of Drill pipe length The drill pipe length, L (see Figure B.1), shall be measured from shoulder to shoulder unless otherwise specified in the purchase agreement. This length shall be recorded and reported to the purchaser. The accuracy of length measuring devices shall be 0.03 m ( 0.1 ft). Drill pipe length determination shall be in metres and hundredths of a metre (feet and tenths of a foot) Straightness All drill pipe shall be visually examined for straightness. The straightness of questionably bent pipes or crooked extremities shall be measured in accordance with End drift test End drift testing shall be performed with a drift mandrel conforming to the requirements of It is permissible for the ends of the drift mandrel, extending beyond the specified cylindrical portion, to be shaped to permit easy entry into the drill pipe. The drift mandrel shall pass freely through the length of the drill pipe tool joint and upset using a manual or power drift procedure. In case of dispute, the manual drift procedure shall be used Internal profile Each end of every drill pipe shall be visually examined for compliance with the requirements of Questionable ends shall be examined using the following method. The weld zone configuration inspection shall be made with a 90 hook-type tool (see Figure B.2). The contact pin shall be visually determined to be attached perpendicular to the handle. The contact point radius shall not exceed the inside radius of the weld zone being inspected. Sharp edges on the contact point shall be removed (see contact point on Figure B.2). The 90 hook-type tool contact point should be maintained perpendicular to the longitudinal axis of the weld zone while the contact point is passed axially throughout the weld zone length. Pressure on the contact point shall be no greater than the pressure created by the weight of the 90º hook-type tool Tool joint alignment Tool joint alignment shall conform to the requirements in and shall be verified according to a documented procedure. A general tool for measurement is illustrated in Figure B Testing of welds Lot size A lot shall consist of all those welds that are produced in a single production run (either continuous or interrupted) on the same welding machine (without any modification of the set-up parameters) using the same qualified procedures (WPS and WPQ) Test specimens Where size allows, all initial test specimens for the weld zone shall be taken from the same sample.

19 6.8 Tensile test Procedures The tensile test shall be performed at room temperature in accordance with ISO 6892 or ASTM A370. Tests may be carried out on semi-finished products before final machining operations but after final heat treatment. The fracture shall not occur at the weld line Test equipment calibration Tensile test machines shall have been calibrated within a period of 15 months preceding any test, in accordance with the procedures in ISO or ASTM E4. Extensometers shall have been calibrated within a period of 15 months preceding any test, in accordance with the procedures in ISO 9513 or ASTM E83. Retention of records shall be in accordance with and Table C.9 or Table D Specimens A longitudinal section of sufficient length to include the entire weld zone shall be suitably prepared and etched to determine the location of the weld zone relative to the weld line and transverse grain flow. This etched section shall be used to ensure that the tensile specimen includes the full weld zone within the reduced section as shown in Figure B.3. The largest possible round bar tensile specimens, in accordance with the requirements of the 0.2 % offset method in ISO 6892 or ASTM A370 shall be taken from the longitudinal section location as shown in Figure B.3. Specimens with a diameter of 12.7 mm (0.500 in.) are preferred. Specimens with a diameter of 8.9 mm (0.350 in.) or 6.4 mm (0.250 in.) are suitable alternatives for thin sections Frequency The tensile test frequency for the weld shall be as in Table C.10 or Table D.10. Additional requirements for PSL-2 and PSL-3 are in Annex G. For an alternative test frequency, see Clause E.6 (SR 23) Defective specimen Specimens showing material imperfections or defective preparation, whether observed before or after testing, may be discarded and replacements shall be considered as original specimens Retests If the initial tensile test fails to conform to the specified requirements, the manufacturer may elect to test two additional specimens from the same weld. If both additional specimens pass, the lot shall be accepted. If one or more of the additional specimens fail to conform to the requirements, the lot shall be rejected. Rejected lots may be re-heat treated and tested as new lots. If insufficient material remains for the retest specimens to be obtained from the original sample, then it is permitted to obtain specimens from another weld within the same lot.

20 6.9 Hardness test Procedures Hardness tests shall be made in accordance with the appropriate standards as follows: a) ISO or ASTM E10; b) ISO or ASTM E92; c) ISO or ASTM E18. Hardness indentations shall not be closer than three indentation diameters from other indentations measured center-to-center Surface hardness test Each weld zone shall be hardness tested on the outside surface at three places, apart. Selection of the hardness testing method is at the manufacturer's option, including the use of an alternative test method. In such a case, the manufacturer shall demonstrate the equivalence of the test result to those of one of the standards mentioned in Surface hardness Retest All welds with a hardness number that exceeds the value specified in shall be re-tested or rejected. For any hardness number that exceeds the specified value, one more hardness test shall be made in the immediate area. If the new hardness number does not exceed the specified value, the weld shall be accepted. If the new hardness number exceeds the specified value, the weld shall be rejected. The manufacturer may elect to re-heat treat the weld in accordance with the same qualified procedure and perform the surface hardness test again Through-wall hardness test The through-wall hardness test frequency of the weld zone shall be as in Table C.10 or Table D.10. A Rockwell mean hardness number is the average of three Rockwell C-scale numbers taken at 2.5 mm to 6.4 mm (0.10 in. to 0.25 in.) from the outside surface and from the inside surface on the pipe and tool joint sides of the weld line (that is 12 hardness numbers and 4 Rockwell mean hardness numbers on each weld. as shown in Figure B.3) Through-wall hardness Retests All weld test pieces with a mean hardness number that exceeds the value specified in shall be retested or the lot represented by the test shall be rejected. Before retesting, the test surface may be reground. If the retest mean hardness numbers do not exceed the specified value, the lot shall be accepted. If any retest mean hardness number exceeds the specified value. the lot of welds represented by the test piece shall be rejected. Rejected lots may be re-heat treated and tested as new lots Charpy V-notch impact test Procedures A test shall consist of a set of three longitudinal specimens taken from one weld. Charpy V-notch impact tests as in ASTM A370 and ASTM E23 shall be conducted at a temperature of 21 C 3 C (70 F 5 F). For alternative standardized test temperatures, see Clause E.5 (SR 20) and PSL-3 in Table C.8 or Table D.8.

21 Tests conducted at any temperature lower than the specified temperature are acceptable provided the absorbed energy requirements at the specified temperature are achieved. Additional requirements for PSL-2 and PSL-3 are in Annex G Specimen size and orientation The impact test specimen shall not be smaller than the largest size shown in Table C.11 or Table D.11 based on the specifed drill pipe weld neck diameter (and rounded to the next smaller specified outside diameter if required) and the calculated weld neck thickness (based on specified dimensions). Specimens shall be removed from the weld longitudinally with respect to the axis of the pipe with the notch oriented in a radial direction as shown in Figure B.3. The center of the notch in the specimen shall be located on the weld line Test frequency The impact test frequency for the weld shall be as in Table C.10 or Table D.10. Additional requirements for PSL-2 and PSL-3 are in Annex G. For an alternative test frequency, see Clause E.6 (SR 23) Re-tests If the requirements of are not met and not more than one specimen is below the minimum specimen absorbed energy requirement, the manufacturer may elect either to reject the lot or to re-test a set of three additional specimens from the same weld test piece. For all three of these specimens, the absorbed energy shall be equal to or greater than the minimum average absorbed energy in Table C.8 or Table D.8, or the lot shall be rejected. If insufficient material remains for the retest specimens to be obtained from the original sample, then it is permitted to obtain specimens from another weld from the same lot. If more than one specimen in the initial test is below the minimum specimen absorbed energy requirement, then the manufacturer may elect either to reject the lot or to retest an additional set of three specimens from each of three additional welds from the same lot. If these additional sets of specimens do not meet the initial test requirements, then the lot shall be rejected. Rejected lots may be re-heat treated and tested as new lots Defective specimens Specimens showing material imperfections or defective preparation, whether observed before or after testing, may be discarded. and replacements shall be considered as original specimens, Specimens shall not be judged defective simply because they fail to exhibit the minimum absorbed energy requirements, 6.11 Transverse side-bend test Procedure The guided bend test shall be carried out in accordance with the ASME BPVC, Section IX, paragraphs QW and QW The specimen shall be bent until the two branches of the specimen form an angle of not greater than 40 under load as shown in Figure B.3. The weld zone shall be completely within the bend portion of the specimen after bending. A test shall consist of one specimen bent in the clockwise direction and another specimen bent in the counter-clockwise direction relative to the pipe axis.

22 Specimens One set of two specimens shall be removed from the weld zone of the test piece. The weld zone shall be in the center of longitudinal specimens. The test specimens shall be of full wall thickness, approximately 9.5 mm ( 3 /8 in.) wide and the length shall be 150 mm (6 in.) minimum Test frequency The transverse side-bend test frequency shall be as in Table C.10 or Table D.10. For an alternative test frequency, see Clause E.6 (SR 23) Retests If only one of the guided-bend specimens fail to conform to the specified requirements, the manufacturer may elect to reject the lot or to test an additional set of two specimens from the same weld test piece. If both retest specimens meet the specified requirements, the lot shall be accepted. If one or both retest specimens fail to meet the specified requirements, the lot shall be rejected. It is preferred that retest specimens be obtained from the same sample as the original test specimen(s). However, if the retest specimens cannot be obtained from the original sample, it is permissible to obtain specimens from another weld within the same lot. Rejected lots may be re-heat treated and tested as a new lot Imperfections and defects in drill pipe General Drill pipe shall be free from defects as defined in this standard Weld zone defects Any weld zone imperfection detected by visual inspection, as in 6.13, or wet fluorescent magnetic-particle inspection, as in , shall be considered a defect. Any imperfection detected by ultrasonic inspection that produces a signal equal to or greater than the signal produced by the reference standard described in shall be considered a defect. Quench cracks shall be considered defects and shall be cause for rejection of the product Process control plan The manufacturer, based on knowledge of the production process and the requirements of 6.13 and 6.14, shall apply a process control plan that ensures compliance with the requirements of Visual inspection of the drill pipe weld zone General Each weld zone shall be visually inspected over the entire outside surface for the detection of defects. This inspection shall be carried out by trained personnel. Visual acuity requirements shall be documented by the manufacturer. Personnel compliance with these requirements shall be documented. NOTE Examples of visual acuity requirements are in ISO or ASNT SNT-TC-1A.

23 Documented lighting standards for visual inspection shall be established by the manufacturer. The minimum illumination level at the inspection surface shall be 500 lux (50 foot-candles). The visual inspection for defects may be at any appropriate point in the manufacturing process after machining Disposition of defects Defects shall be completely removed by grinding or machining. All grinding shall be blended smooth. The dimensions after grinding shall comply with the requirements of Non-destructive examination of the weld zone General All NDE operations (except visual inspection) referred to in this standard shall be conducted by NDE personnel qualified in accordance with ISO or ASNT SNT-TC-1A. The manufacturer or inspection company shall have the training program to qualify or certify the NDE personnel for the method, technique, and equipment that are used for the inspection(s) specified in this standard. Surfaces to be inspected shall be machined and, if necessary, ground before inspection. When specified in the purchase agreement, the provisions for purchaser inspection of the weld zone and/or witnessing of NDE operations shall be in accordance with Annex D. The inspections performed in accordance with 6.14, with the equipment calibrated to the specified reference indicators, should not be construed as assuring that the material requirements in 6.12 have been met. The manufacturer shall determine the appropriate NDE equipment verification frequency to certify that all products conform to the requirements of this standard Wet fluorescent magnetic particle inspection The entire outside surface of the weld zone shall be wet-fluorescent-magnetic-particle inspected for the detection of transverse imperfections in accordance with ISO or ASTM E709. Wet particle concentration shall be checked every 8 hr or each shift change. The minimum black-light intensity at the examination surface shall not be less than 1000 µw/cm Ultrasonic inspection Procedure Each weld zone shall be ultrasonically inspected from the pipe side around the circumference with the beam directed toward the weld. Shear wave/angle beam ultrasonic equipment capable of inspection of the entire weld zone shall be used. The inspection shall be applied in accordance with the manufacturer s documented procedure. The instrument gain setting during inspection shall not be set lower than the gain setting when checked against the reference standard. In case of dispute, the transducer used shall generate a square 2.25 MHz frequency attached to a 45 5 acrylic wedge (refers to the entry angle in the material) Ultrasonic inspection Reference Standard A reference standard shall be used to demonstrate the effectiveness of the inspection equipment and procedures at least once every working shift. The equipment shall be adjusted to produce a well-defined indication when the reference standard is scanned in a manner simulating the inspection of the product. The reference standard shall have the same specified diameter and wall thickness and the same acoustic properties and surface finish as the weld zone being inspected and may be of any convenient length as